Electrical Plug Connector Ribs for Lateral Force Resistance
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Solution Overview
Problem
Existing electrical connectors are prone to damage due to external forces, particularly lateral forces, which can deform and damage the contact sleeve and spring tongues during connector insertion or removal.
Innovation Solution
The electrical connector features three axially extending ribs on its outer circumference, evenly spaced in the circumferential direction, which protrude radially outward to support the contact sleeve within the housing, preventing damage from diagonal tensile forces and ensuring stable contact even under external stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the contact sleeve and spring tongues are designed without additional support structures, then the device complexity is reduced and manufacturing is easier, but the connector becomes prone to deformation and damage when subjected to lateral forces during insertion or removal
Solution Approach 1:
The contact sleeve is segmented with multiple ribs (at least three) extending radially outward from its outer circumference. These ribs divide the structural reinforcement function into discrete elements distributed around the sleeve, providing enhanced lateral support without requiring a completely different structural approach. The segmentation allows the sleeve to maintain its basic cylindrical form while adding localized support features.
Solution Approach 2:
The ribs are positioned asymmetrically relative to the spring tongues, with specific spacing relationships defined (e.g., at least one rib between adjacent spring tongues when viewed in axial direction). This asymmetric arrangement optimizes the distribution of lateral forces across the contact sleeve structure, providing targeted reinforcement where needed while maintaining manufacturing feasibility.
2Strength
If the contact spring tongues are made more rigid to resist deformation, then the mechanical strength is improved, but the electrical contact quality may deteriorate due to reduced elasticity and contact pressure
Solution Approach 1:
The spring tongues are designed with non-uniform cross-sectional properties along their length. The cross-section varies from the base to the free end, with different thickness or width characteristics in different axial regions. This local variation allows the tongue to have increased rigidity near the base (resisting deformation) while maintaining flexibility and elastic contact pressure at the free end (ensuring reliable electrical contact).
Solution Approach 2:
The spring tongues are designed to exhibit dynamic elastic behavior, allowing them to deflect and recover in response to insertion forces and operational vibrations. The rib structures provide static support while the spring tongues maintain dynamic flexibility, creating a hybrid system that combines rigidity where needed with elasticity where required for reliable electrical contact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The ribs provide uniform support and prevent deformation of the contact sleeve and spring tongues, maintaining electrical and mechanical integrity even when subjected to diagonal forces, thus enhancing the connector's resistance to damage from external forces.
Implementation Method 1
at least one spring-loaded deflectable contact spring tongue with a free end is arranged and designed on the shell wall of the contact sleeve such that the free end projects radially inwards beyond the shell wall of the contact sleeve and forms a contact surface for electrical and mechanical contacting of the mating connector
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an electrical plug connector having a hollow cylindrical housing (10) and having a contact sleeve (12) in the form of a hollow cylinder having a casing wall (14), which contact sleeve is arranged radially inside the housing (10), for producing a mechanical and an electrical contact with a counterpart connector (100),wherein at least one contact spring tongue (16) which can be deflected resiliently and has a free end (20) is arranged on the casing wall (14) of the contact sleeve (12) and is configured in such a way that the free end (20) projects in the radially inward direction beyond the casing wall (14) of the contact sleeve (12) and forms a contact surface (22) for electrical and mechanical contacting of the counterpart connector (100). At least three ribs (24) are formed on an outer periphery of the casing wall (14) of the contact sleeve which project beyond the casing wall (14) in a radially outward direction.